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Toyota Wiring (1991-2005 year). Instruction - part 6

Sleeve

Color Marks

Crimping
Tool

”CLOSE HERE”

Contact

”INS” Position

10 mm (0.39 in.)

Three or More Times

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Instruction (RM1022E)

(b)

The crimping tool (AMP Part No. 169060) has color
marks on it. Place the sleeve in the correct section of
the tool according to the color of the sleeve itself.

HINT:

For the crimping tool, AMP ”Part No. 169060” is

convenient to use.

(c)

With the center of the sleeve correctly placed
between the crimping jaws, squeeze the crimping tool
until either end comes into contact at the section
marked by ”CLOSE HERE”.

HINT:

Check to see that the sleeve and wires are still in

the correct position before closing the crimping tool ends
with steady pressure.

(d)

Pull the joined wires to either end. Make sure that they
are joined firmly by the sleeve.

NOTICE:
If the joined wires come loose the splice is defective,
so replace the sleeve and repeat the procedure.

(e)

Crimp both ends of the sleeve with the crimping tool
at the ”INS” position.

Protect Joined Section

Wrap silicon tape around the joins to protect them from
moisture.

NOTE: This job is required in repairs of the engine
compartment, under the floor and other moisture entry
positions.

Three or More Times

10 mm (0.39 in.)

Tape overlapping

10 mm (0.39 in.)

Two or More Times

Finish

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

HINT:

Before starting the operation, thoroughly wipe dirt and
grease off the sections to be joined.

If the adhesive surfaces of two tapes come in contact
they will stick together and will not come apart, so do
not remove the backing film except when using the
tape.

Do not let oil and dust, etc. get on the tape surface.

(a)

Ready about 100 mm (3.94 in.) of silicon tape (Part
No. 08231–00045) and peel off the film.

(b)

Stretch the silicon tape until its width is reduced by
half.

(c)

About 10 mm (0.39 in.) from the end of the sleeve,
wrap the silicon tape around the sleeve three or more
times while stretching the tape.

(d)

Wrap the remaining part of the sleeve with half of the
tape overlapping at each turn.

(e)

Firmly wrap the tape two times or more about 10 mm
(0.39 in.) from the other end of the sleeve, then wrap
the tape back towards the start again and firmly finish
winding the tape around the center of the sleeve.

Special Tool

Locking clip

Special Tool

Terminal Lance

”Insulation Displacement Connector”

Terminal Lance

”0.64 Type”

Special Tool

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Instruction (RM1022E)

Step 4.

Install the terminal into the connector.

HINT:

(a)

Make sure the terminal is positioned correctly.

(b)

Insert the terminal until the locking clip locks firmly.

(c)

Insert the terminal with terminal retainer in the
temporary lock position, if equipped.

NOTE: If reusing a terminal, check that the locking clip is
still in good condition and in the proper position.

(a)

If it is on the terminal and not in the proper position,
use the special tool to gently bend the locking clip
back to the original shape.

(b)

Check that the other parts of the terminal are in their
original shape.

NOTICE:
Do not readjust or reuse the terminal lance of the
insulation displacement connector type terminal.
Always change the wire with the repair wire.

NOTICE:
As for 0.64 type terminal, do not adjust the terminal
lance with the special tool.

Splash Proof Type Connector

NOTICE:

Removal of the terminal from housing cavity will
cause damage to rubber plug material (the wire
seal), deteriorating waterproofing performance. Be
sure to replace the housing with a new one.

Check the withdrawn terminal for the following if
trying to use it again.

It is free of deformation and damage

It is free of adherents such as rubber plug
material (wire seal)

Replace any deformed terminal.

Wire

”Click”

”0.64 IDC Type”

”Click”

”Insulation
Displacement
Connector”

Good Example:

Bad Example:

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Push the Terminal into the Connector until you
hear a ”click”.

NOTE: Not all terminals will give and audible ”click”.

NOTICE:

After repairing, never let only one harness stretch.

In cese that it becomes short, do over again using
the repair wire.

Terminal Retainer

Example:

Good

Bad

Good

Bad

[Female]

[Male]

∗

Terminal
In Short
Position

∗

Terminal
In Short
Position

Double Locking
Device

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

B–34

Wire Harness Repair Instruction (RM1022E)

Double Locking Type Connector
(with terminal retainer or double locking device)

The connector is fitted with a terminal retainer, or a double
locking device, it is in the temporary lock position at insert
the terminal.

Type A (For 1.0, 1.0II, 1.3, 1.8, 2.3II 4.8 and 8.0 of
Non–Waterproof Type Connector)

(a)

Insert the terminal.

HINT:
1.

Make sure the terminal is positioned correctly.

Insert the terminal with terminal retainer in the
temporary lock position.

(b)

Insert the terminal until the locking clip locks firmly.

HINT:

Pull the terminal back gently to check whether it is
locked correctly.

If it cannot be inserted easily, check the terminal and
the connector for damage.

NOTE: If the terminal to locking clip does not lock firmly,
the double locking device cannot lock or terminal retainer
does not lock at full lock position so the terminal backs out
from connector.

(c)

Close terminal retainer or double locking device.

The connector is fitted with a terminal retainer, or a
double locking device, return it to the full lock position.

Full Lock Position

[Female]

Full Lock Position

[Female]

Full Lock Position

[Male]

Terminal Retainer
at Temporary
Lock Position

Terminal Locking
Clip

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

Type B (For 1.8, 2.3, 2.3II, 4.8, 6.3 and 8.0 of Waterproof
Type)
(For Male Connector)

(a)

Insert the terminal.

HINT:

Make sure the terminal is positioned correctly.

Insert the terminal with terminal retainer in the
temporary lock position.

(b)

Insert the terminal until the locking clip locks firmly.

HINT:

Pull the terminal back gently to check whether it is
locked correctly.

If it cannot be inserted easily, check the terminal and
the connector for damage.

Bad Example:

Terminal in Short
Position

Terminal
Locking Clip

Terminal
Retainer

[Case 1]

Full Lock Position

[Case 2]

Full Lock Position

Terminal Locking Clip

Terminal Retainer
at Temporary Lock
Position

TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

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Wire Harness Repair Instruction (RM1022E)

NOTE: If the terminal to locking clip does not lock firmly,
terminal retainer can not lock at full lock position so the
terminal backs out from connector.

(c)

”For Case 1”
Push the terminal retainer in to the full lock position.

”For Case 2”
Raise the terminal retainer up to the full lock position.

(For Female Connector)

(a)

Insert the terminal.

HINT:
1.

Make sure the terminal is positioned correctly.

Insert the terminal with terminal retainer in the
temporary lock position.

Bad Example:

Terminal in Short
Position

Terminal
Locking
Clip

[Case 1]

Full Lock Position

[Case 2]

Full Lock
Position

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TERMINAL AND CONNECTOR REPAIR–TERMINAL REPLACEMENT

Wire Harness Repair Instruction (RM1022E)

(b)

Insert the terminal until the locking clip locks firmly.

HINT:

Pull the terminal back gently to check whether it is
locked correctly.

If it cannot be inserted easily, check the terminal and
the connector for damage.

NOTE: If the terminal to locking clip does not lock firmly,
terminal retainer can not lock at full lock position so the
terminal backs out from connector.

(c)

”For Case 1”
Push the terminal retainer in to the full lock position.

”For Case 2”
Raise the terminal retainer up to the full lock position.

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